Methods for forming implantable signal generators with molded headers

ABSTRACT

Molded headers, implantable signal generators having molded headers, and associated systems and methods are disclosed herein. An implantable signal generator in accordance with a particular embodiment includes a can having a shell and a battery positioned at least partially within the shell. An output terminal can be operably coupled to the battery and positioned to provide electrical power to a signal delivery device. A pre-molded header having a plurality of openings can be coupled to the can, and the output terminal can be positioned at least partially within an individual opening.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation application of U.S. patentapplication Ser. No. 14/981,463, filed Dec. 28, 2015 and titled “MOLDEDHEADERS FOR IMPLANTABLE SIGNAL GENERATORS, AND ASSOCIATED SYSTEMS ANDMETHODS,” which is a continuation of U.S. patent application Ser. No.14/268,575, filed May 2, 2014, and titled “MOLDED HEADERS FORIMPLANTABLE SIGNAL GENERATORS, AND ASSOCIATED SYSTEMS AND METHODS,”which claims priority to U.S. Provisional Application No. 61/819,347,filed May 3, 2013, and titled MOLDED HEADERS FOR IMPLANTABLE SIGNALGENERATORS, AND ASSOCIATED SYSTEMS AND METHODS. U.S. ProvisionalApplication No. 61/819,347 is related to U.S. patent application Ser.No. 13/669,350, filed Nov. 5, 2012, and titled MEDICAL DEVICECOMMUNICATION AND CHARGING ASSEMBLIES FOR USE WITH IMPLANTABLE SIGNALGENERATORS, AND ASSOCIATED SYSTEMS AND METHODS, which claims priority toU.S. Provisional Application 61/556,097, filed Nov. 4, 2011, and titledMEDICAL DEVICE COMMUNICATION AND CHARGING ASSEMBLIES FOR USE WITHIMPLANTABLE PULSE GENERATORS, AND ASSOCIATED SYSTEMS AND METHODS. Theentirety of the above applications, and U.S. Design patent applicationSer. No. 29/436,395, filed Nov. 5, 2012, and titled IMPLANTABLE SIGNALGENERATOR, are incorporated by reference herein. To the extent theforegoing applications and/or any other materials incorporated herein byreference conflict with the present disclosure, the present disclosurecontrols.

TECHNICAL FIELD

The present technology is directed generally to molded headers,implantable signal generators having molded headers, and associatedsystems and methods. Molded headers in accordance with the presenttechnology are suitable for securing and/or encapsulating one or morecomponents of an implantable signal generator, including charging coilsand communications antennas.

BACKGROUND

Neurological stimulators have been developed to treat pain, movementdisorders, functional disorders, spasticity, cancer, cardiac disorders,and various other medical conditions. Implantable neurologicalstimulation systems generally have an implantable signal generator(sometimes referred to as an “implantable pulse generator” or “IPG”)that is operably coupled to one or more leads that deliver electricalsignals or pulses to neurological tissue or muscle tissue. For example,several neurological stimulation systems for spinal cord stimulation(SCS) have cylindrical leads that include a lead body with a circularcross-sectional shape and multiple conductive rings spaced apart fromeach other at the distal end of the lead body. The conductive ringsoperate as individual electrodes or contacts to deliver electricalsignals to the patient. The SCS leads are typically implanted eithersurgically or percutaneously through a needle inserted into the epiduralspace, often with the assistance of a stylet.

Once implanted, the signal generator applies electrical signals to theelectrodes, which in turn modify the function of the patient's nervoussystem, such as by altering the patient's responsiveness to sensorystimuli and/or altering the patient's motor-circuit output. Inparticular, the electrical signals can generate sensations that mask orotherwise alter the patient's sensation of pain. For example, in manycases, patients report a tingling or paresthesia that is perceived asmore pleasant and/or less uncomfortable than the underlying painsensation. In other cases, the patients can report pain relief withoutparesthesia or other sensations. As used herein, unless explicitlystated otherwise, the terms “pulses” and “signals” are usedinterchangeably to include any waveform shapes, whether continuous ordiscontinuous, including but not limited to sinusoidal or non-sinusoidalwaves such as square waves, triangle waves, sawtooth waves, etc.

Implantable signal generators generally include a communication antennathat allows operational parameters of a stimulation system to bealtered, without necessitating a hard-wired external connection.Additionally, implantable signal generators often include a chargingcoil that allows a battery in the implantable signal generator to berecharged from an external power source. The design of the communicationantenna and the charging coil, and their locations within theimplantable signal generator, can significantly impact the performanceof the stimulation system. If the antenna and/or the coil are poorlypositioned or shielded, updating operational parameters and/or chargingthe implantable signal generator can be difficult or impossible. Forexample, in many existing systems it can be difficult for a patient oran operator to correctly position an external device to transmit signalsto the implantable signal generator. Additionally, poor coil design orshielding interference can decrease the efficiency of the chargingprocess and cause increased heating. Metal shells or casings thatimplantable signal generators often include can at least partiallycontribute to the effects described above. Positioning the communicationantenna and/or charging coil outside of the casing can often partiallyalleviate some of these concerns. However, externally positionedcomponents can increase the complexity and costs associated with themanufacturing of a device. Prior systems suffer from many of theseand/or additional drawbacks.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially schematic illustration of an implantable spinalcord modulation system positioned at a patient's spine to delivertherapeutic signals in accordance with an embodiment of the presenttechnology.

FIG. 2A is a partially schematic isometric view of an implantable signalgenerator having a molded header and a can configured in accordance witha further embodiment of the present technology.

FIG. 2B is a partially cutaway side view of a portion of the implantablesignal generator of FIG. 2A.

FIG. 3A is an isometric view of a molded header configured in accordancewith an embodiment of the present technology.

FIG. 3B is an isometric view of the header of FIG. 3A having multiplecovers configured in accordance with an embodiment of the presenttechnology.

FIG. 4 is an isometric view of an implantable signal generator having amolded header configured in accordance with a further embodiment of thepresent technology.

FIGS. 5A and 5B are isometric and cross sectional side views,respectively, of a set screw block configured in accordance with anotherembodiment of the present technology.

FIGS. 6A-6C are isometric views of molded headers configured inaccordance with embodiments of the present technology.

DETAILED DESCRIPTION

The present technology is directed generally to communication andcharging assemblies for medical devices, and more specifically tocommunication and charging assemblies for implantable neurologicalmodulation systems. At least some embodiments of the present technologyinclude implantable signal generators having a header configured tosupport communication antennas, charging coils and/or other components.The header can be constructed to support multiple components and providefor the manufacturing of implantable signal generators via proceduresthat, when compared to existing manufacturing techniques, reduce theassociated complexity and/or costs. For example, headers in accordancewith the present technology can facilitate simultaneously connectingmultiple components to an implantable signal generator. Additionally,the reduced costs associated with the present technology can enable theeconomical production of implantable signal generators that provideimproved, enhanced, more robust and/or more effective signal receptionand/or generation, as well as enhanced charging efficiency and decreasedheat generation.

Embodiments in accordance with the present technology can includedevices, systems and associated methods that have differentconfigurations, components, and/or procedures. Still other embodimentsmay eliminate particular components and/or procedures. The presenttechnology, which includes associated devices, systems, and procedures,may include other embodiments with additional elements or steps, and/ormay include other embodiments without several of the features or stepsshown and described below with reference to FIGS. 1-6C. Several aspectsof overall systems configured in accordance with the disclosedtechnology are described with reference to FIG. 1, and features specificto particular molded headers are then discussed with reference to FIGS.2A-6C.

FIG. 1 schematically illustrates a representative patient system 100 forproviding relief from chronic pain and/or other conditions, arrangedrelative to the general anatomy of a patient's spinal cord 191. Theoverall patient system 100 can include a signal delivery device 110,which may be implanted within a patient 190, typically at or near thepatient's spinal cord midline 189, and coupled to a signal generator 101(e.g., a pulse generator). The signal delivery device 110 carriesfeatures for delivering therapy to the patient 190 after implantation.The signal generator 101 can be connected directly to the signaldelivery device 110, or it can be coupled to the signal delivery device110 via a signal link or lead extension 102. In a further representativeembodiment, the signal delivery device 110 can include one or moreelongated lead(s) or lead body or bodies 111. As used herein, the terms“lead” and “lead body” include any of a number of suitable substratesand/or support members that carry devices for providing therapy signalsto the patient 190. For example, the lead or leads 111 can include oneor more electrodes or electrical contacts that direct electrical signalsinto the patient's tissue, such as to provide for patient pain relief.In other embodiments, the signal delivery device 110 can includestructures other than a lead body (e.g., a paddle) that also directelectrical signals and/or other types of signals to the patient 190.

The signal generator 101 can transmit signals (e.g., electrical signalsor therapy signals) to the signal delivery device 110 that up-regulate(e.g., stimulate or excite) and/or down-regulate (e.g., block orsuppress) target nerves. As used herein, and unless otherwise noted, to“modulate” or provide “modulation” to the target nerves refers generallyto having either type of the foregoing effects on the target nerves. Thesignal generator 101 can include a machine-readable (e.g.,computer-readable) medium containing instructions for generating andtransmitting suitable therapy signals. The signal generator 101 and/orother elements of the system 100 can include one or more processor(s)107, memory unit(s) 108 and/or input/output device(s) 112. Accordingly,the process of providing therapy signals, providing guidance informationfor positioning the signal delivery device(s) 110, and/or executingother associated functions can be performed by computer-executableinstructions contained by computer-readable media located at the signalgenerator 101 and/or other system components. The signal generator 101can include multiple portions, elements, and/or subsystems (e.g., fordirecting signals in accordance with multiple signal deliveryparameters), carried in a single housing, as shown in FIG. 1, or inmultiple housings.

In some embodiments, the signal generator 101 can obtain power togenerate the therapy signals from an external power source 103. Theexternal power source 103 can transmit power to the implanted signalgenerator 101 using electromagnetic induction (e.g., RF signals). Forexample, the external power source 103 can include an external coil 104that communicates with a corresponding internal coil (not shown) withinthe implantable pulse generator 101. The external power source 103 canbe portable for ease of use.

In the course of at least some overall procedures, an externalstimulator or trial modulator 105 can be coupled to the signal deliverydevice 110 during an initial procedure, prior to implanting the signalgenerator 101. For example, a practitioner (e.g., a physician and/or acompany representative) can use the trial modulator 105 to vary thetherapy parameters provided to the signal delivery device 110 in realtime, and select optimal or particularly efficacious parameters. Theseparameters can include the location from which the electrical signalsare emitted, as well as the characteristics of the electrical signalsprovided to the signal delivery device 110. In a typical process, thepractitioner uses a cable assembly 120 to temporarily connect the trialmodulator 105 to the signal delivery device 110. The practitioner cantest the efficacy of the signal delivery device 110 in an initialposition. The practitioner can then disconnect the cable assembly 120(e.g., at a connector 122), reposition the signal delivery device 110,and reapply the electrical therapy. This process can be performediteratively until the practitioner obtains the desired position for thesignal delivery device 110. Optionally, the practitioner may move thepartially implanted signal delivery element 110 without disconnectingthe cable assembly 120. In at least some embodiments, the iterativeprocess of repositioning the signal delivery device 110 and/or varyingthe therapy parameters may be unnecessary and therefore eliminated.

The pulse generator 101, the lead extension 102, the trial modulator 105and/or the connector 122 can each include a receiving element 109.Accordingly, the receiving elements 109 can be patient implantableelements, or the receiving elements 109 can be integral with an externalpatient treatment element, device or component (e.g., the trialmodulator 105 and/or the connector 122). The receiving elements 109 canbe configured to facilitate a simple coupling and decoupling procedurebetween the signal delivery devices 110, the lead extension 102, thepulse generator 101, the trial modulator 105 and/or the connector 122.Receiving elements 109 can be at least generally similar in structureand function to those described in U.S. patent application Ser. No.13/291,985, entitled MEDICAL DEVICE CONTACT ASSEMBLIES FOR USE WITHIMPLANTABLE LEADS, AND ASSOCIATED SYSTEMS AND METHODS, filed Nov. 8,2011, which is incorporated by reference herein in its entirety.

After a trial period with the trial modulator 105, the practitioner canimplant the implantable signal generator 101 within the patient 190 forlonger term treatment. The signal delivery parameters provided by thesignal generator 101 can still be updated after the signal generator 101is implanted, via a wireless physician's programmer 117 (e.g., aphysician's laptop, physician's remote, etc.) and/or a wireless patientprogrammer 106 (e.g., a patient's laptop, a patient's remote, etc.).Generally, the patient 190 has control over fewer parameters than doesthe practitioner.

FIG. 2A is a partially schematic isometric view of an implantable signalgenerator 200 having a molded header 202 and a can 204 configured inaccordance with an embodiment of the present technology. Many of theembodiments described below include pre-formed or pre-molded headershaving pre-formed openings in which a manufacturer can position one ormore components. In other embodiments, headers can be formed in an insitu molding process that includes molding a header into a shape andsimultaneously encasing components within the header during the moldingprocess.

FIG. 2B is a partially cutaway side view of a portion of the implantablesignal generator 200 of FIG. 2A. Referring to FIGS. 2A and 2B together,the can 204 may include a rounded rectangular shell 206 and an ovalshaped lid 208 positioned at least partially between the header 202 andthe can 204. In one embodiment, the shell 206 and the lid 208 can betitanium, and a weld joint can join the lid 208 to the shell 206. Inother embodiments, the shell 206 and the lid 208 can be made of othermetals or metal alloys, or plastic, and can be joined together by othermethods including press fitting, adhesive materials and/or threadedconnections. In any of these embodiments, the lid 208 can include aplurality of feed-throughs 212 for electrical communication between theheader 202 and the can 204.

The molded header 202 can be formed from Tecothane®, Elast-Eon™,silicone, polymers, copolymers and/or any other suitable material, andcan be attached to the can 204. The header 202 can house, support,and/or carry several components. For example, the molded header 202 cancarry a charging coil 224, a communication antenna 222, a firstreceiving element 216 a and a second receiving element 216 b(collectively, receiving elements 216). These and several othercomponents can be at least partially enclosed, encompassed, containedand/or otherwise positioned within the header in a variety of manners.

The receiving elements 216 can include a plurality of output terminalsor contact assemblies 218, configured to provide electrical connectionsto the signal delivery device 110 (FIG. 1) or the lead extension 102(FIG. 1). Additionally, a first set screw block 219 a and a second setscrew block 219 b can be integral with or connected to the receivingelements 216 a and 216 b, respectively. The first set screw block 219 aand the second set screw block 219 b (collectively, set screw blocks219) can provide for the securement of the signal delivery device 110 orthe lead extension 102, as further described below. The communicationantenna 222 and the charging coil 224 can be shaped, positioned, and/orotherwise configured to enhance the performance of the implantablesignal generator 200, while fitting within the confines of the header202 (as discussed in more detail in U.S. patent application Ser. No.13/669,350, which was incorporated by reference above). Multiple wires226 can extend upwardly from the can 204 through the feed-throughs 212and couple to (a) individual contact assemblies 218, (b) thecommunication antenna 222, or (c) the charging coil 224.

The wires 226 can provide electrical connections between componentswithin the header 202, e.g., the charging coil 224 and the communicationantenna 222, and components within the can 204, e.g., a battery 230, acontroller 232, etc. The battery 230 can be electrically coupled to thecontroller 232 and the output terminals or contact assemblies 218 toprovide electrical power to the implantable signal generator 200 via thereceiving elements 216. The battery 230 can be recharged via anelectrical coupling to the charging coil 224. The controller 232 can beelectrically coupled to the contact assemblies 218 and the battery 230,and can include a processor 234, memory 236, electronic circuitry, andother electronic components for controlling and/or operating theimplantable signal generator 200. Computer readable instructionscontained in the memory 236 can include operating parameters andinstructions that can control the operation of the implantable signalgenerator 200. In operation, the charging coil 224 can convertelectromagnetic energy (e.g., a magnetic flux) into electrical currentto charge the battery 230. The communication antenna 222 can receivesignals associated with operating and/or controlling the implantablesignal generator 200. For example, control signals to update operatingparameters (e.g., the frequency or duration of modulation signals) forthe implantable signal generator 200 can be received by thecommunications antenna 222 and sent to the controller 232. Thecontroller 232 can control the delivery of electrical power to thereceiving elements 216.

The header 202 includes a first access seal 217 a and a second accessseal 217 b (collectively referred to as the access seals 217). Theaccess seals 217 include a self-sealing entrance point to provide accessfor a tool (e.g., a screwdriver) to secure a connection (e.g., a screw)to the signal delivery device 110 (FIG. 1) or the lead extension 102(FIG. 1) via the set-screw blocks 219. The access seals 217 can beformed from a pliable silicone or other suitable material such that thetool can pass through and expand the entrance point. When the tool iswithdrawn, the entrance point can automatically close to reduce oreliminate the possibility of any foreign material (e.g., blood or otherbodily fluids) subsequently entering into the header 202.

The header 202 can be attached to the can 204 in a variety of suitablemanners. For example, in one embodiment, the header 202 can be attachedto the lid 208 (FIG. 2B) with an adhesive. In other embodiments, the lid208, the can 204 and/or other components can include a groove, and theheader 202 can include a ring that can engage the groove.

FIG. 3A is an isometric view of a molded header 302 configured inaccordance with an embodiment of the present technology. In theillustrated embodiment, a body 301 of the header 302 includes a curvedor rounded upper surface 305, a base 303 and a plurality of cutouts orpre-formed openings 304. The openings 304 can be shaped to accommodatevarious components that can be positioned within the header 302 (e.g.,receiving elements, charging coils, communication antennas, and/or otherelectronic, electrical or electromechanical components, etc.). Theopenings 304 can at least partially enclose, encompass and/or containthe components within the header 302. In several embodiments, componentscan be positioned within or at least partially within the header 302 andthe header 302 can maintain the components in a desired position duringsubsequent attachment to the can 204. For example, the charging coil224, the communication antenna 222 and/or the receiving elements 216 andthe associated output terminals 218 can be received or positioned withinthe openings 304. The header 302 can help to align the wires 226 withthe feed-throughs 212 (FIG. 2B), and/or align other connections orcomponents of the can 204 with components positioned within the header302. Maintaining the position of one or more components can reduce thecomplexity of the process for manufacturing the implantable signalgenerator 200, as described below. Additionally, the openings 304 canallow the manufacturer to precisely position the components within theheader 302, which can provide several operational advantages for theimplantable signal generator, as also described below.

Although the illustrated embodiments include wires 226 (FIG. 2B) thatconnect components in the header 202 or 302 with components in the can204, components of the implantable signal generator 200 can be connectedin a variety of suitable manners. For example, in some embodiments, thecommunication antenna 222, the charging coil 224, the receiving elements216 and/or other components can include various wires, connectors, plugsand/or other features that provide for electrical coupling. In someembodiments, the components in the header 202 or 302 (e.g., thereceiving elements 216, the charging coil 224 and the communicationantenna 222) can include plugs that can be inserted into receptaclespositioned on or attached to the lid 208.

In several embodiments, the header 302 can facilitate connectingmultiple components in one step. For example, one method ofmanufacturing an implantable signal generator can include positioningmultiple components in the openings 304 of the header 302 with multiplewires, connectors and/or plugs extending therefrom. The header 302 cansubsequently be aligned with and brought together with the can 204(FIGS. 2A and 2B), simultaneously establishing electrical connectionsbetween the components in the header 302 and components in the can 204via connections with the multiple wires, connectors or plugs. In otherembodiments, wires from more than one component can be carried by asingle connector or plug that provides a connection between componentsin the header 202 or 302 and components in the can 204.

The molded headers 202 and 302 of FIGS. 2A-3B can be formed in a varietyof manners. For example, a representative process includes constructinga mold having a desired header shape and injecting a liquid materialinto the mold, thereby forcing the liquid into the shape of the header.The liquid can be cured via cooling and/or other processes to form asolid header. A variety of molding techniques, including injectionmolding, compression molding, etc. can be used to mold the headers 202and 302. In some embodiments, the molding process can include formingthe openings 304, e.g., via mold inserts or other techniques. Theopenings 304 can also be formed after a header has been molded. Forexample, the openings 304 can be formed by cutting or otherwise removingmaterial from a header 202 or 302. Additionally, the headers 202 and 302can be formed to match the shape of at least a portion of the can 204,the shell 206 and/or the lid 208. For example, the molded headers 202and 302 can include the oval shaped base 303 that matches and/or alignswith the shape of the can 202, the shell 206 and the lid 208.

FIG. 3B is an isometric view of the header 302 having multiple covers306 configured in accordance with an embodiment of the presenttechnology. In the illustrated embodiment, the covers 306 are positionedover two of the openings 304. Similar to the header 302, the covers 306can be constructed from a variety of materials (e.g., Tecothane®,Elast-Eon™, silicone, polymers, copolymers and/or any other suitablematerial) and can cover or seal one or more of the openings 304. Forexample, in some embodiments, the covers 306 can be constructed of thesame material as the header 302 and can be adhered to the header 302 viamedical adhesive to cover or seal one or more of the openings 304.Although the illustrated embodiment includes covers that are positionedover the openings 304, in several embodiments, the covers 306 can bepositioned partially or completely within the openings 304. The covers306 can be coupled to the body 301 of the header 302 in various suitablemanners. For example, thermal bonding, compression fitting and/or othertechniques or procedures can adhere the covers 306 to the header 302.The covers 306 can be permanently attached to the header 302 to remainin position after implantation of an associated implantable signalgenerator and at least partially seal the header 302, reducing thelikelihood of foreign material (e.g., blood or other bodily fluids)entering the header 302. The covers 306 can be applied to headers otherthan the header 302 shown in FIGS. 3A and 3B, e.g., the header 202 shownin FIGS. 2A and 2B and/or headers described further below.

FIG. 4 is an isometric view of an implantable signal generator 400having a molded header 402 configured in accordance with an embodimentof the present technology. In the illustrated embodiment, the header 402includes a first header portion 404 a and a second header portion 404 b(collectively, the header portions 404) that can be configured andjoined in a clamshell arrangement. The header 402, overall, can be atleast generally similar to the header 302 and can include multipleopenings for receiving components. Similarly, the openings in the header402 can be covered or sealed with covers (e.g., the covers 306 of FIG.3B). Components (e.g., charging coils, communication antennas, receivingelements, etc.) can be positioned within the header 402 before or afterthe header portions 404 are coupled together. For example, in someembodiments, the header portions 404 can be joined together andcomponents can then be positioned therein in a manner at least generallysimilar to that described above with respect to the header 302.

In other embodiments, components can be positioned within the header 402as the coupleable header portions 404 are joined together. For example,the header portions 404 can be brought together to capture and/or atleast partially surround the receiving elements 216 (FIG. 2A) and/orother components. Furthermore, the header portions 404 can be joinedtogether before or after the header 402 is coupled to the can 204. Forexample, the first header portion 404 a can be coupled to the can 204first, and the second header portion 404 b can be subsequently coupledto both the can 204 and the first header portion 404 a. The headerportions 404 can be coupled or joined together in a variety of suitablemanners or techniques. For example, thermal bonding, medical adhesiveand/or other suitable materials, processes and/or methods may be used tojoin the header portions 404.

FIG. 5A is an isometric view of a set screw block 500 configured inaccordance with an embodiment of the present technology. Similar to theset screw blocks 219 described above with respect to FIG. 2B, the setscrew block 500 can be integral with or connected to an output terminalor receiving element (e.g., the receiving elements 216). FIG. 5B is across-sectional side view of the set screw block 500. Referring to FIGS.5A and 5B together, the set screw block 500 includes a receiving passage502 and a fastener conduit 504. The receiving passage 502 includes afunnel shaped, tapered sidewall 506. The receiving passage 502 canreceive an electrical connector or plug that is integral with orconnected to a proximal end of one of the components of the patientsystem 100 described above with reference to FIG. 1. For example, theplug can be integral with any of the signal delivery devices 110described above, e.g., the leads 111. The plug can facilitate anelectrical connection between the leads 111 and the implantable signalgenerators 200 and 400. In several embodiments, the receiving elementscan receive plugs or conductor assemblies that are at least generallysimilar to those described in U.S. patent application Ser. No.13/291,985 which, as described above, is incorporated by referenceherein.

The funnel shaped sidewall 506 of the set screw block 500 can facilitateinsertion of plugs or conductor assemblies. For example, a practitioneris not required to ensure perfect alignment of a plug with the receivingpassage 502. Rather, as the practitioner inserts the plug into thereceiving passage 502, the funnel shaped sidewall 506 can engage theplug and guide the plug to the center of the receiving passage 502.

The fastener conduit 504 can receive a variety of fasteners to secure aplug of conductor assembly within the set screw block 500. For example,the fastener conduit 504 can receive a screw that can engage a plugwithin the receiving passage 502, removably securing the plug within areceiving element. In some embodiments, the fastener conduit 504 caninclude threads (not shown) to engage set screws or other fasteners. Inthe illustrated embodiment, the fastener conduit 504 does not includethreads, and the set screw can include threads that engage correspondingthreads on a plug positioned within the receiving passage 502. Inseveral embodiments, the fastener conduit 504 can receive otherfasteners to secure plugs. For example, press-fit plugs or othercomponents can be positioned within the fastener conduit 504 to secure aplug.

Molded headers in accordance with the present technology can have avariety of suitable shapes and configurations. FIGS. 6A, 6B and 6C areisometric views of molded headers 600 a, 600 b and 600 c, respectively,configured in accordance with embodiments of the present technology. Inthe illustrated embodiment of FIG. 6A, the molded header 600 a has arounded rectangular shape. The molded header 600 b of FIG. 6B has acurved shape with a low profile, while the molded header 600 c of FIG.6C includes a triangular shape. Similar to the molded headers 202, 302and 402 described above, the molded headers 600 a-600 c can include oneor more openings 602 positioned to receive various components. While theshapes and the various openings 602 of the headers 600 a-600 c representparticular embodiments of the present technology, numerous additionalheaders having shapes and/or openings that differ from the illustratedembodiments are within the scope of the present disclosure.

Embodiments in accordance with the present technology can provideseveral advantages over existing devices. For example, as describedabove with reference to FIGS. 3A and 3B, the pre-formed openings 304 canenable the components to be precisely positioned within an implantablesignal generator. This precise positioning can produce increasedperformance by reducing the likelihood of electrical shorts and/or otherdamage resulting from inadvertent contact between components, therebyimproving the reliability of the implantable signal generator.Additionally, the precisely positioned components of the presenttechnology can reduce electromagnetic interference, shielding and/orother detrimental effects. Furthermore, positioning components withinthe pre-formed openings 304 can enable more components to be positionedoutside of the implantable signal generator, thereby providing foradvanced designs and enhanced capabilities. For example, the openings304 can enable a variety of designs that position components in variousthree dimensional spatial relationships to each other within a header.In several embodiments, components can be stacked, staggered, orotherwise positioned to increase the number of components within aheader.

In addition to the advantages discussed above, implantable signalgenerators and/or molded headers in accordance with the presenttechnology can be particularly beneficial for systems employing highfrequency modulation. For example, the signals and operationalparameters of high frequency systems can require greater power usagethan traditional SCS systems. The increased charging efficiency ofimplantable signal generators having charging coils positioned within aheader can help meet greater power requirements without necessitatinglonger charge times (as described in U.S. patent application Ser. No.13/669,350, of which the present application is a continuation-in-part).The technology described herein can reduce the manufacturing complexityand costs of such implantable signal generators, facilitating theeconomical production of these devices. Accordingly, several embodimentsin accordance with the present technology can be combined with highfrequency modulation systems, including those described in U.S. patentapplication Ser. No. 12/264,836, filed Nov. 4, 2008, and titledMULTI-FREQUENCY NEURAL TREATMENTS AND ASSOCIATED SYSTEMS AND METHODS;U.S. patent application Ser. No. 12/765,747, filed Apr. 22, 2010, andtitled SELECTIVE HIGH-FREQUENCY SPINAL CORD MODULATION FOR INHIBITINGPAIN WITH REDUCED SIDE EFFECTS AND ASSOCIATED SYSTEMS AND METHODS; andU.S. patent application Ser. No. 13/607,617, filed Sep. 7, 2012, andtitled SELECTIVE HIGH FREQUENCY SPINAL CORD MODULATION FOR INHIBITINGPAIN, INCLUDING CEPHALIC AND/OR TOTAL BODY PAIN WITH REDUCED SIDEEFFECTS, AND ASSOCIATED SYSTEMS AND METHODS. The above referenced patentapplications are incorporated herein by reference in their entireties.

From the foregoing, it will be appreciated that specific embodiments ofthe disclosed technology have been described herein for purposes ofillustration, but that various modifications may be made withoutdeviating from the technology. For example, in addition to, or in lieuof, an adhesive or a ring and groove arrangement that can secure aheader to a can, a header can include a portion that can at leastpartially extend into the shell. In one embodiment, the lid can bepositioned below the opening of the can, and a portion of the header canbe received within the resulting space. Additionally, although theembodiment of FIG. 4 describes a header 402 having two header portions404, other headers in accordance with the present technology can includeadditional header portions. Other materials may be used in place ofthose described herein, or additional components may be added orremoved. For example, although the illustrated embodiments include aheader having two receiving elements, other embodiments can includeadditional receiving elements, or other connectors. Additionally, any ofthe embodiments shown or described herein may be combined with eachother as the context permits.

Representative Embodiments

In one embodiment, there is provided an implantable signal generator,comprising: (a) a can having a shell and a battery positioned at leastpartially within the shell; (b) an output terminal operably coupled tothe battery and positioned to provide electrical power to a signaldelivery device; and (c) a pre-molded header coupled to the can andhaving a plurality of openings, wherein the output terminal ispositioned at least partially within an individual opening. Thepre-molded header of the implantable signal generator can comprise apolymer. The pre-molded header can also comprise a first header portionand a second header portion, wherein the first and second headerportions are coupleable to form the pre-molded header.

The implantable signal generator can further comprise a cover positionedover at least one of the plurality of openings to at least partiallyseal the pre-molded header. A set screw block can be positioned at leastpartially within the pre-molded header, and the set screw block caninclude a receiving passage having a funnel shaped sidewall. An accessseal can be positioned to provide access to the set screw block.

The individual opening can be a first individual opening, and theimplantable signal generator can further comprise: (d) a charging coil;and (e) a communication antenna. The charging coil can be operablycoupled to the battery and positioned at least partially within a secondindividual opening. The communication antenna can be positioned at leastpartially within a third individual opening to receive control signals.

The implantable signal generator can further comprise a charging coilpositioned within the pre-molded header, wherein the pre-molded headerincludes a curved surface, and wherein the charging coil is shaped to atleast partially match the curved surface.

In another embodiment, there is provided a pre-molded header for animplantable signal generator. The pre-molded header comprises: (a) abody having a rounded upper surface and a base shaped to align with ashell of the implantable signal generator; and (b) an opening positionedto contain an electrical component. The opening can be a first openingshaped to receive a charging coil, and the pre-molded header can furthercomprise a second opening shaped to receive a communication antenna. Thebody of the pre-molded header can comprise a polymer. The pre-moldedheader can include a cover affixed to the body over the opening. Theelectrical component can comprise a charging coil shaped to match therounded upper surface.

In yet another embodiment, there is provided a method for forming animplantable signal generator, comprising: (a) inserting an electroniccomponent at least partially within a pre-formed opening in a pre-moldedheader; and (b) attaching the pre-molded header to a can having a shelland a lid. Inserting an electronic component at least partially withinthe pre-formed opening can include inserting a charging coil at leastpartially within the pre-formed opening, prior to attaching thepre-molded header to the can. The method can further comprisepositioning a battery within the can, and attaching the pre-moldedheader to the can may include aligning the header with the can andestablishing an electrical connection between the charging coil and thebattery.

The electronic component can be a charging coil shaped to at leastpartially match a rounded upper surface of the pre-molded header, andinserting an electronic component at least partially within thepre-formed opening can include inserting the charging coil at leastpartially within the pre-formed opening.

The method may further comprise: attaching a cover to the pre-moldedheader to seal the pre-formed opening; positioning a communicationantenna at least partially within a second pre-formed opening, prior toattaching the pre-molded header to the can; and/or positioning a setscrew block at least partially within the pre-molded header to receivean electrical connector, wherein the set screw block includes areceiving passage having a tapered sidewall.

In another embodiment, there is provided a method for forming apre-molded header for an implantable signal generator having a can. Themethod can comprise forming a body having a plurality of openingspositioned to receive electronic components and a base shaped to atleast partially match a shape of the can. Forming the body can includeforming an external shape of the body using a molding process. Formingthe pre-molded header can further include: forming the body to include arounded upper surface; and/or forming the body to include an openingshaped to receive a charging coil having a shape that at least partiallymatches the rounded upper surface. Forming the body can include: formingthe plurality of openings as part of the molding process; forming theplurality of openings after the molding process; and/or forming a firstindividual opening as part of the molding process and forming a secondindividual opening after the molding process. The method may compriseproviding a cover shaped to affix to the body and seal an individualopening.

While various advantages and features associated with certainembodiments have been described above in the context of thoseembodiments, other embodiments may also exhibit such advantages and/orfeatures, and not all embodiments need necessarily exhibit suchadvantages and/or features to fall within the scope of the technology.Accordingly, the disclosure and associated technology can encompassother embodiments not expressly shown or described herein.

We claim:
 1. A method for forming an implantable signal generator, themethod comprising: providing a can; positioning one or more cancomponents in the can; providing a header having multiple openings;positioning multiple header components in respective ones of themultiple openings of the header, including: two receiving elements eachcomprising multiple cylindrical contact assemblies; and multipleparallel conductors each extending linearly between the can and acorresponding contact assembly; aligning the header with the can; andsimultaneously establishing electrical connections between the multipleheader components and the one or more can components via the conductors.2. The method of claim 1, wherein positioning one or more can componentsin the can includes positioning a battery in the can.
 3. The method ofclaim 1, wherein positioning multiple header components in respectiveones of the multiple openings of the header includes inserting acharging coil at least partially within a corresponding one of themultiple openings.
 4. The method of claim 3, wherein the charging coilis shaped to at least partially match a rounded upper surface of theheader.
 5. The method of claim 3, wherein positioning multiple headercomponents in respective ones of the multiple openings of the headerincludes inserting a communication antenna at least partially within acorresponding one of the multiple openings.
 6. The method of claim 1,further comprising attaching a cover to the header to seal at least oneof the multiple openings.
 7. A method for forming an implantable signalgenerator, the method comprising: providing a can comprising a shell anda lid having multiple feed-throughs extending therethrough; positioningone or more can components in the can; providing a header havingmultiple openings; positioning multiple header components in respectiveones of the multiple openings of the header, including: two receivingelements each comprising multiple cylindrical contact assemblies; andmultiple parallel conductors each extending linearly between the lid anda corresponding contact assembly; aligning the header with the can; andsimultaneously engaging each conductor with a corresponding one of themultiple feed-throughs.
 8. The method of claim 7, wherein positioningmultiple header components in respective ones of the multiple openingsof the header includes inserting each of a charging coil and acommunication antenna at least partially within a corresponding one ofthe multiple openings.
 9. A method for forming an implantable signalgenerator, the method comprising: providing a can; positioning one ormore can components in the can; molding a header including multipleheader components encased at least partially within the header duringthe molding process, the header components including: two receivingelements each comprising multiple cylindrical contact assemblies; andmultiple parallel conductors each extending linearly between the can anda corresponding contact assembly; aligning the header with the can; andsimultaneously establishing electrical connections between the multipleheader components and the one or more can components via the conductors.10. The method of claim 9, wherein the can comprises a shell and a lidhaving multiple feed-throughs extending therethrough.
 11. The method ofclaim 10, wherein simultaneously establishing electrical connectionsbetween the multiple header components and the one or more cancomponents includes simultaneously engaging each conductor with acorresponding one of the multiple feed-throughs.
 12. The method of claim9, wherein the multiple header components include a charging coil and acommunication antenna.